Vermont Castings Merrimack Large Wood Insert User manual

Vermont Castings • Merrimack Large Insert Owner’s Manual_R15 • 11/18 13-90-30004671
For Use in North America
Merrimack Large Wood Insert
Owner’s Manual
Operation & Care
INSTALLER: Leave this manual with party responsible for use and operation.
OWNER: Retain this manual for future reference.
Contact your dealer with questions on installation, operation, or service.
If the information in these instructions is not
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property damage, personal injury, or death.
WARNING
!
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and liquids in the vicinity of this or any other appliance.
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warranty.
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HOT SURFACES!
Glass and other surfaces are hot
during operation AND cool down.
Hot glass will cause burns.
WARNING
!
• Do not touch glass until it is cooled
• NEVER allow children to touch glass
• Keep children away
• &$5()8//<683(59,6(FKLOGUHQLQVDPHURRPDV
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• Alert children and adults to hazards of high
temperatures
• High temperatures may ignite clothing or other
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• Keep clothing, furniture, draperies and other
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NOTE
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contact your dealer or visit www.vermontcastings.com
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vous plaît contacter votre revendeur ou visitez www.
vermontcastings.com
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Vermont Castings • Merrimack Large Insert Owner’s Manual_R15 • 11/18 23-90-30004671
Introduction
Save These Instructions for Future Reference
The Merrimack Large Insert is designed, tested and
listed for burning wood. Do not burn other fuels.
The Merrimack Large Insert is not listed for mobile
home installations.
Failure to follow these instructions may result in
property damage, bodily injury or even death.
6SHFL¿FDWLRQV .........................................................3
Dimensions.............................................................4
,QVWDOODWLRQ ..............................................................5
Smoke Alarm/Safety Tip.........................................9
2SHUDWLRQ..............................................................10
Maintenance.........................................................12
2SWLRQDO$FFHVVRULHV ............................................17
Service Parts List..................................................18
Warranty...............................................................21
Table of Contents
Proposition65Warning:)XHOVXVHGLQJDVZRRGEXUQLQJ
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of such fuels, contain chemicals known to the State
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reproductive harm.
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$JHQF\VHPLVVLRQOLPLWVIRUZRRGKHDWHUVVROGDIWHU0D\8QGHUVSHFL¿FWHVWFRQGLWLRQVWKLVKHDWHUKDVEHHQVKRZQ
to deliver heat at a rate ranging from 10,750 to 31,780 BTU/hr.
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WARNING
!
This stove has not been tested with an unvented gas
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= Contains updated information
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!WARNING
This product and the fuels used to operate this product
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H[SRVH \RX WR FKHPLFDOV LQFOXGLQJ FDUERQ EODFN ZKLFK
is known to the State of California to cause cancer, and
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California safety information
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Vermont Castings • Merrimack Large Insert Owner’s Manual_R15 • 11/1833-90-30004671
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during EPA emission test.
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during EPA emission test.
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and the burn rates from the low and high EPA tests, using
Douglas Fir dimensional lumber.
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This wood heater needs periodic inspection and repair for
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this wood heater in a manner inconsistent with operating
instructions in this manual.
MODEL: 0HUULPDFN/DUJH,QVHUW
LABORATORY: 201,7HVW/DERUDWRULHV,QF
REPORT NO. 6
TYPE: 6ROLG)XHO5RRP+HDWHU:RRG
Burning Type
STANDARD(s): 8/5
8/&6$
ELECTRICAL
RATING: 9$&+]
Area Heated................................6TXDUHIHHW
Loading.......................................................................Front
Chimney Connector:......................................PP
Flue Exit Position .........................................................Top
Primary Air ......................................................
Manually Set
Glass Panels...........................+LJK7HPSHUDWXUH&HUDPLF
Weight......................................................OEVNJ
Blower Rating .................................FIP9+]
Power Cord Lenght .....................)RRW8VHDEOH,QVWDOOHG
(3$&HUWL¿FDWLRQ1XPEHU 770
(3$&HUWL¿HG(PLVVLRQV JKU
/+97HVWHG(I¿FLHQF\ 73.0%
++9WHVWHG(I¿FLHQF\ 
***EPA BTU Output: 
****Peak BTU/Hour Output: 55,800
Other Important Information
Vent Size: ,QFKPP
Firebox Size: 3.1 cu. ft.
Max. Wood Length: 0D[LPXP
Ideal Wood Length: 
Fuel Seasoned Cordwood
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Vermont Castings • Merrimack Large Insert Owner’s Manual_R15 • 11/1843-90-30004671
Figure 10HUULPDFN/DUJH,QVHUWGLPHQVLRQV
2956” (740 mm)
246M” (629 mm)
126QE”
(313 mm)
266QE”
(668 mm)
17556QE” (449 mm)
2356QE”
(605 mm)
76QE”
(183 mm)
3156O" (800 mm) 256” (645 mm)
Dimensions

Vermont Castings • Merrimack Large Insert Owner’s Manual_R15 • 11/18 53-90-30004671
SAFETY NOTICE: IF YOUR MERRIMACK IS NOT
PROPERLYINSTALLED,AHOUSEFIREMAYRESULT.TO
REDUCETHERISKOFFIRE,FOLLOWTHEINSTALLATION
INSTRUCTIONS. CONTACT LOCAL BUILDING OR FIRE
OFFICIALSABOUTRESTRICTIONSANDINSTALLATION
INSPECTION REQUIREMENTS IN YOUR AREA.
Requirements for Existing Fireplaces
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Codes may permit removal of the damper in order to make
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toitsoriginalcondition if the insert isremoved.Donot remove
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The Merrimack Large Insert is not approved for
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Requirements for Existing Chimneys
Chimney requirements differ for the U.S. and Canada.
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to the chimney in accordance with local codes and the
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Chimney Height / U.S. and Canada
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DO NOT CONNECT YOUR MERRIMACK LARGE INSERT
TO A CHIMNEY FLUE SERVING ANOTHER APPLIANCE.
Installation
In the U.S. (ANSI/NFPA 211, 1988), when installed in a
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liner.
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to the chimney cavity.
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General Considerations / U.S.
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Vermont Castings Group strongly recommends that
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inserttothechimneytoptoincreaseoverallperformance
and to ease and reduce yearly maintenance.
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should have a FRGHDSSURYHGOLQHUPDGHRIPDVRQU\
RUSUHFDVWUHIUDFWRU\ tilesVWUDLJKWRUÀH[LEOHVWDLQOHVV
VWHHOSLSHRUDSRXUHGLQSODFHOLQHU$QXQOLQHGFKLPQH\
PXVWEHUHOLQHGSURIHVVLRQDOO\
 7KHFKLPQH\PXVWKDYHDQRPLQDOÀXHVL]HRI
PPGLDPHWHURUVTXDUHLQFKHVFP2EXWQR
JUHDWHUWKDQWLPHVODUJHURUVTXDUHLQFKHV
cm2$FKLPQH\ODUJHUWKDQWKLVPXVWEHUHOLQHG
2' Min.
2' Min.
3'
Min.
0 To 10'
3'
Min.
0 To 10'
Reference
Point
Figure 27KHUXOHIRUFKLPQH\V
Î

Vermont Castings • Merrimack Large Insert Owner’s Manual_R15 • 11/183-90-30004671
Fireplace Minimums
AWidth at Face ´PP
B:LGWKDW'LPHQVLRQµ&¶ ´PP
CDepth1´PP
D+HLJKWDW)DFH ´PP
E+HLJKWDW'LPHQVLRQµ&¶ ´PP
Fireplace Maximums
HLintel Depth ´PP
IWidth2´PP
J+HLJKW2´PP
 7KHPLQLPXPGHSWKPXVWEHPDLQWDLQHGIURPWKHÀRRURIWKH¿UHSODFH
WRDKHLJKWRI´PP
 7KRXJKWKH0HUULPDFN/DUJH,QVHUWZLOO¿WLQWRODUJHU¿UHSODFHVWKH
decorative optional Vermont Castings Group Surround Panels will
QRWFRPSOHWHO\FRYHUWKH¿UHSODFHRSHQLQJLIWKHVHGLPHQVLRQVDUH
H[FHHGHG&XVWRPPDGHWULPSLHFHVPD\EHXVHG
A,I
BC
D,J
E
D,J
H
CE
Figure 38VHWKHVHPHDVXUHPHQWVWRFRQ¿UPWKDWWKH0HUULPDFN
/DUJH,QVHUWZLOO¿WLQWR\RXUPDVRQU\¿UHSODFH
Minimum Fireplace Dimensions
7KH0HUULPDFN/DUJH,QVHUWZLOO¿WPDQ\¿UHSODFHV7RFRQ¿UP
WKDWLWZLOO¿W\RXUVPHDVXUHWKHOLQWHOGHSWKSOXVWKHKHLJKW
ZLGWKDQGGHSWKRI\RXU¿UHSODFHDQGKHDUWK&RPSDUHWKHP
WRWKHPHDVXUHPHQWVLQWKHDFFRPSDQ\LQJFKDUW,I\RXFKRRVH
WRLQVWDOODQHZKHDUWKRYHUDQH[LVWLQJ¿UHSODFHKHDUWKEH
sureto take itsthickness into considerationwhen measuring
ERWKIURQWDQGEDFNKHLJKWRIWKH¿UHSODFHDQGFOHDUDQFHVWR
any existing trims and mantels.
NOTE: 7KHFOHDUDQFHEHWZHHQWKH0HUULPDFN/DUJH,QVHUW
DQGWKHPDQWHOWRSWULPDQGVLGHWULPFDQQRWEHUHGXFHGE\
installing shields.
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LWHPV VXFK DV WDEOHV ERRNFDVHV UXJV IXUQLVKLQJV DQG
\RXUZRRGER[$OOFRPEXVWLEOHPDWHULDOVRIWKLVW\SHVKRXOG
EHDPLQLPXPRIPPIURPWKHIURQWVXUIDFHRI
WKH0HUULPDFN/DUJH,QVHUW%HVXUHWKDWIDPLO\PHPEHUV
are aware of this requirement as well, so they too will keep
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%HDZDUHWKDWDFKLPQH\RULJLQDOO\GHVLJQHGIRU¿UHSODFHXVH
PD\SHUIRUPGLIIHUHQWO\ZKHQXVHGWRYHQWDQDLUFRQWUROOHG
DSSOLDQFH VXFK DV \RXU 0HUULPDFN /DUJH ,QVHUW  HYHQ LI
WKHÀXHLVOHVVWKDQWLPHVODUJHUWKDQWKHÀXHFROODU)RU
example, a chimney on an outside wall may not heat up
HQRXJKWRVXVWDLQDQDGHTXDWHGUDIW6XFKDÀXHFDQRIWHQ
EHLPSURYHGLILWLVUHOLQHGWRUHGXFHLWVVL]HDQGRULQVXODWHG
to keep it warmer.
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,QVHUW DQG WKH ¿UVW PDVRQU\ WLOH RU SUHIDEULFDWHG PHWDO
FKLPQH\VHFWLRQ$ SRVLWLYH ÀXH FRQQHFWLRQ FRQVLVWV RI
DSODWHWKDWVHDOVRUUHSODFHVWKH¿UHSODFHGDPSHUDQG
a section of chimney connector that passes through the
plate into the chimney.
 7KHFKLPQH\FRQQHFWRUPXVWEHDPLQLPXPHTXLYDOHQWWR
DPPGLDPHWHURSHQLQJDQGPXVWEHJDXJH
or heavier stainless steel.
&KLPQH\&RQQHFWLRQV\VWHPVDUHDYDLODEOHIURPDYDULHW\
of manufacturers. Your Vermont Castings dealer can
UHFRPPHQGDV\VWHPWKDWZLOOEHVWPHHWWKHUHTXLUHPHQWV
of your particular installation.
Sealing Requirements / U.S.
 7KHFKLPQH\PXVWEHVHDOHGRIIIURPURRPDLUHLWKHUE\
DSODWHDWWKHGDPSHUOHYHORUE\VHDOLQJWKH¿UHSODFH
opening.
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PDVRQU\WRWKHWKLFNQHVVRIWKHFKLPQH\ZDOO2SHQLQJV
VHDOHGZLWKSLHSODWHV RUZDOOSDSHUDUHDKD]DUG,Q
WKHHYHQWRIDFKLPQH\¿UHÀDPHVDQGVPRNHPD\
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In Canada (CAN/CSA-B365-M91, Section 5):
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FKLPQH\OLQHURIPPGLDPHWHUH[WHQGLQJIURPWKH
¿UHSODFHLQVHUWWRWKHWRSRIWKHFKLPQH\7KHFKLPQH\
liner must conform to the Class 3 requirements of CAN/
8/&6 6WDQGDUG IRU /LQLQJ 6\VWHPV IRU ([LVWLQJ
0DVRQU\RU)DFWRU\%XLOW&KLPQH\VDQG9HQWV, or CAN/
8/&66WDQGDUGIRU/LQLQJ6\VWHPVIRU1HZ0DVRQU\
&KLPQH\V.
 7KHRSHQLQJRIWKH¿UHSODFHDURXQGWKHLQVHUWPXVWEH
VHDOHGWRSUHYHQWURRPDLUSDVVLQJWRWKH¿UHSODFHFDYLW\
 ([LVWLQJDLUFLUFXODWLRQFKDPEHUVLQD¿UHSODFHZLWKDVWHHO
OLQHUPD\QRWEHEORFNHG
 3URYLVLRQPXVWEHPDGHIRUUHPRYDORIWKHLQVHUWWRFOHDQ
WKHFKLPQH\ÀXH
 7KHH[LVWLQJ¿UHSODFHGDPSHULIDQ\VKRXOGEHORFNHG
in the open position.
 $SHUPDQHQWPHWDOZDUQLQJODEHOPXVWEHDI¿[HGWRWKH
EDFNRIWKH¿UHSODFHVWDWLQJWKH¿UHSODFHPD\KDYHEHHQ
DOWHUHGWRDFFRPPRGDWHWKHLQVHUWDQGPD\EHXQVDIHWR
XVHDVDFRQYHQWLRQDO¿UHSODFH$)LUHSODFH0RGL¿FDWLRQ
7DJLVLQFOXGHGLQWKHKDUGZDUHEDJLQVLGHWKH0HUULPDFN
/DUJH,QVHUW

Vermont Castings • Merrimack Large Insert Owner’s Manual_R15 • 11/18 73-90-30004671
Clearance Requirements
$IWHUFRQ¿UPLQJWKDW\RXU¿UHSODFHLVWKHULJKWVL]HFKHFN
WKHFOHDUDQFHWRFRPEXVWLEOHV)LUVWPDUNZLWKWDSHWKHH[DFW
FHQWHURI\RXU¿UHSODFHRSHQLQJRQWKHKHDUWK0HDVXUHWKH
side clearance from this point. Measure the top trim and/or
PDQWHOFOHDUDQFHVIURPWKH¿QLVKHGKHDUWKVXUIDFH0HDVXUH
WKHIURQWFOHDUDQFHWRIXUQLVKLQJVHWFIURPWKH¿UHSODFH
IDFH)LJXUH
X
C
A
B
Measure
side trim
clearance
from here
Fireplace Clearances
 $0DQWHO  PP
 %7RS7ULP´  PP
 &6LGH7ULP ´ PP
&OHDUDQFHVKRZQLVIRUPPGHHSPDQWHO'LPHQVLRQPD\
EHUHGXFHGWRPPLIWKHPDQWHOLVPPGHHSRUOHVV
** Where side trim extends more than 1
1»2
PPIURPWKH¿UHSODFH
IDFLQJWKHVLGHFOHDUDQFHPXVWEHQROHVVWKDQ
1»4
PPWKLVLV
also the required side wall clearance.
0HDVXUHWKHVLGHFOHDUDQFH&IURPWKHH[DFWFHQWHURI\RXU¿UHSODFH
RSHQLQJ RQ WKH KHDUWK ; 0HDVXUH WKH WRS WULP % DQGRU PDQWHO
FOHDUDQFHV $ IURP WKH ¿QLVKHG KHDUWK VXUIDFH 0HDVXUH WKH IURQW
FOHDUDQFHWRIXUQLVKLQJVHWFIURPWKH¿UHSODFHIDFH
Figure 42EVHUYHWKHVHFOHDUDQFHVWRFRPEXVWLEOHWULP
Hearth Requirements
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LVEULFNVWRQHVODWHRUVRPHRWKHUQRQFRPEXVWLEOHPDWHULDO
thatisindirectcontactwithconcretepouredoverearth.These
DUHWKHRQO\KHDUWKVWKDWDUHFRQVLGHUHGQRQFRPEXVWLEOH,Q
RWKHU¿UHSODFHVWKHEULFNRUFRQFUHWHKHDUWKLQIURQWRIWKH
¿UHSODFHRSHQLQJ LV VXSSRUWHG E\ KHDY\ ZRRGHQ IUDPLQJ
%HFDXVH QHLWKHU EULFN QRU FRQFUHWH KDV JRRG LQVXODWLQJ
SURSHUWLHV KHDW UDGLDWHG E\ WKH ¿UH ZLOO SDVV GRZQZDUG
through the hearth to the wooden framing. Such hearths are
FRQVLGHUHGFRPEXVWLEOH
7KHKHDUWKIRUWKH0HUULPDFNLQVHUWPXVWEHFRQVWUXFWHGRYHU
DFRPSOHWHO\QRQFRPEXVWLEOHVXUIDFHVXFKDVXQSDLQWHG
FRQFUHWHRYHUHDUWK7KLVQRQFRPEXVWLEOHKHDUWKPXVWH[WHQG
DWOHDVWPPLQIURQWRIWKHGRRUVDVSURWHFWLRQIURP
KHDWUDGLDWHGIURPWKHLQVHUW7KLVPHDQVWKHQRQFRPEXVWLEOH
KHDUWKPXVWH[WHQGLQIURQWRIWKH¿UHSODFHIDFHRSHQLQJ
in a typical installation.
,QDGGLWLRQVSDUNDQGHPEHUSURWHFWLRQLVQHHGHG
PPWRHDFKVLGHRIWKHLQVHUWDQGLQ&DQDGDLQIURQWRI
the insert. The approved construction of this protection is a
minimum or 24 gauge galvanized sheet metal or equivalent.
Figure 5 shows the details of hearth requirements.
A
C
BB
7”
(178 mm)
United States Canada
 $  PP  PP
 %  PP  PP
 & ´PP ´ PP
Figure 58QOHVV\RXU¿UHSODFHDQGKHDUWKDUHFRQVWUXFWHGRYHU
DGLUWÀRRURUXQSDLQWHGFRQFUHWHRYHUGLUW\RXPXVWXVHDÀRRU
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How to Determine if Alternate Floor Protection
Materials are Acceptable
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specified includes some form of thermal designation
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Procedure:
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inches:
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inches:
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protector:
i. Use the formula in Step 1 to convert values not
expressed as R.
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1
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1
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Vermont Castings • Merrimack Large Insert Owner’s Manual_R15 • 11/1883-90-30004671
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Step c: 1»8PLQHUDOERDUGRIN WKHUHIRUH
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Step d: Rtotal 5EULFN + RPLQHUDOERDUG  
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R of 1.79. Since proposed system Rtotal is less than
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Optional Surround Packages
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Vermont Castings Group offersasteelorcast iron surround
panel kit.
Installing the Merrimack Large Insert
1. Remove or Disable the Fireplace Damper. ,IFRGHV
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screw.
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secure the damper in the fully open position.
~ NOTE: CANADIAN INSTALLATIONS ~
In accordance with CAN/CSA B365-M91, you must
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2. Fluecollarorientation:7KHÀXHFROODUPD\EHRULHQWHG
intheverticalpositionorrotated180degreesonthetop
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methodforyourapplication, the center iron pulldownhandle
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metal cutting saw.
3. Install the venting system: Again, depending on your
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holes using the holes in the iron collar as a guide.
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same method.
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This will allow an easy connection once the stove is
rolled into place.
4. Route the blower power cord. Run the power cord out
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you run the power cord out the left side, remove the two
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insert the provided grommet into the slot. Reattach the
cover plate.

Vermont Castings • Merrimack Large Insert Owner’s Manual_R15 • 11/18 93-90-30004671
Figure 70HDVXUHGKHLJKWIURPWKH¿QLVKHGKHDUWKVXUIDFHWRWKH
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2056O”
(521 mm)
Ref. 26”
3RVVLEOH+DQGOH
Bracket Locations
Mantel
Access
Door
Bracket and
Screws Bracket
and Screws
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8. Connect the Flue Collar: From inside the stove, reach
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left. Secure these in place with the stainless steel cotter
pins.
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sides of the stove.
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cotter pin.
9. Connect the Blower power cord to the power supply.
DO NOT ROUTE THE POWER CORD UNDER OR IN
FRONT OF THE UNIT.
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Smoke and CO Detectors
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throughout the home is strongly advised, even if not
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maintain regularly.
You may not, however, wish to install a detector in the
immediate vicinity of the Montpelier insert. Depending on
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detector in the same room, locate it as far away from the
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Safety Tips
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• Evacuate the house immediately
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5. Install Mantel and Access Door. For enamel units:
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upper lattice is not even, you can pull the doors mantel
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6. InstalltheOptionalSurroundKit.Followtheinstructions
provided with the kit.
7. Roll the Firebox into Position. At least two people will
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the front of the stove slightly to put weight on the rear
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the connector. Use the leveling screws at the front of the
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nearest the power supply.

Vermont Castings • Merrimack Large Insert Owner’s Manual_R15 • 11/1810 3-90-30004671
Operation
Your Insert's Controls and What They Do
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Three controls regulate the performance of your Merrimack
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The primary air controlVXSSOLHVR[\JHQIRUWKH¿UH
7KHYDULDEOHVSHHGfan control, or rheostat, regulates the
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automaticallyoncethestovereachesoperatingtemperatures.
Air Control
Lever Open -
Control Lever to the Left
Closed -
Control Lever to the Right
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Air Control Lever
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Space Between
Doors and Upper
Lattice
Jacking
Screws
Jacking
Screws
Speed Control
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toAccess Fan controls
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WARNING
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regulations to alter this setting or otherwise operate this
wood heater in a manner inconsistent with operating
instructions in this manual.
The Fans
The convection fan delivers a steady stream of warm air into
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a cold stove, this switch will typically energize the fan within
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Primary Air Control
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Theprimaryaircontrolleverislocatedontheupperleftside
on the front of the insert. The lever regulates air for starting,
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the control lever is moved to the left, and decreased when
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two extremes, depending on the amount of heat desired.
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To complement the manual setting of the air control, the
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that ensures an even delivery of heat at the manual setting
you select.